Design and Implementation of Model Predictive Control Based PID Controller for Industrial Applications

Advanced control approaches are essential for industrial processes to enhance system performance and increase the production rate. Model Predictive Control (MPC) is considered as one of the promising advanced control algorithms. It is suitable for several industrial applications for its ability to handle system constraints. However, it is not widely implemented in the industrial field as most field engineers are not familiar with the advanced techniques conceptual structure, the relation between the parameter settings and control system actions. Conversely, the Proportional Integral Derivative (PID) controller is a common industrial controller known for its simplicity and robustness. Adapting the parameters of the PID considering system constraints is a challenging task. Both controllers, MPC and PID, merged in a hierarchical structure in this work to improve the industrial processes performance considering the operational constraints. The proposed control system is simulated and implemented on a three-tank benchmark system as a Multi-Input Multi-Output (MIMO) system. Since the main industrial goal of the proposed configuration is to be easily implemented using the available automation technology, PID controller is implemented in a PLC (Programable Logic Controller) controller as a lower controller level, while MPC controller and the adaptation mechanism are implemented within a SCADA (Supervisory Control And Data Acquisition) system as a higher controller level.